Deck spacer

ABSTRACT

Disclosed herein is a spacing device utilized in the construction of decks and the like from composite building planks. The spacing device generally comprises a straight length of material possessing a T-shaped cross-section. The vertical element (or leg) of the “T” is used to establish the space between the polymer planks of a deck. The horizontal element prevents the spacer from falling through the space established by the T&#39;s leg. The spacing device is fabricated of a strong, lightweight material such as aluminum to provide the durability and portability required by the nature of its usage. The present invention&#39;s design is simple and straightforward, and can be economically manufactured and sold.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application derives priority from U.S. ProvisionalApplication Ser. No. 60/350,093 filed Jan. 18, 2002.

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] The present invention relates to tools used for home improvementand construction and, more particularly, to a spacer device for use inthe construction of decks and the like using polymer building materials.

[0004] 2. Description of the Background

[0005] There are a number of composite materials used in fabricatingdecking. One of the first composites introduced was Trex®, a combinationof furniture sawdust mixed with plastic from Owens Corning. Trex®requires virtually no maintenance, comes with a lifetime warranty anddoes not need to be sealed. Newer composite lumbers include:TimberTech®, SmartDeck™ and Dreamworks™. The maintenance-free aspects ofthese composites has helped them to gain widespread acceptance in recentyears. Aluminum and PVC are also good artificial decking materials aswell. However, in all the above cases the deck planking is subject toexpansion and contraction in hot weather. In addition, planks that arepressed tight can trap moisture and encourage rot. Consequently, thecarpenter must carefully space the individual deck planks beforesecuring them to create a gap for air and drainage. This is currentlydone with nails by inserting a nail between the planks at each joist andpounding it slightly into the joist. The planks are then butted tightand nailed down, right on each joist. Proper spacing in this mannerensures that the decking can accommodate warp, that it will provideadequate water drainage, and that it will have proper aesthetics (e.g. auniform look/feel). Once the next plank is fully installed, the“spacing” nails are removed for reuse. The shallow indentations, in theunderlying beams, left after the spacing nails have been removed do notcause any short- or long-term structural harm to the deck. However, theuse of nails is time-consuming because a plurality of nails must beinserted individually lengthwise along each plank and pounded in to staythere. The nails must later be individually removed. There are knownspacers that simplify deck spacing to an extent. For example, the DeckSpacer available at http://www.deckspacer.com/purports to saves time andlabor of laying deck boards, ensures even spacing throughout the deck,and offers both ⅛″ and ¼″ spacing. However, the carpenter must stillcarry and apply a plurality of Deck Spacers lengthwise along each plankto ensure uniform spacing.

[0006] Therefore, there remains a need for a spacing device configuredfor use with composite decking planks which increases the carpentersproductivity on the job by taking the guesswork out of spacing. To thebest of the knowledge of the present inventor, a spacing device meetingthese requirements does not exist. A device of this type should beergonomic (i.e. durable, lightweight) to optimize its “ease of use” andeconomical to manufacture and sell to ensure widespread use.

SUMMARY OF THE INVENTION

[0007] It is, therefore, the primary object of the present invention toprovide an improved spacing device for positioning the polymer planks ofa deck or the like in a consistent manner for utilitarian and aestheticpurposes.

[0008] It is another object of the present invention to provide animproved spacing device that is ergonomic and multi-functional.

[0009] Still another object of the present invention is to provide animproved spacing device that is economical to manufacture.

[0010] These and other objects are accomplished by a spacing device thatgenerally comprises a straight length of material possessing a T-shapedcross-section. The vertical element (or leg) of the “T” is used toestablish the space between the polymer planks of a deck. The horizontalelement prevents the spacer from falling through the space establishedby the T's leg. The spacing device of the present invention isfabricated of a strong, lightweight material such as aluminum to providethe durability and portability required by the nature of its usage. Thepresent invention's design is simple and straightforward, and can beeconomically manufactured and sold.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Other objects, features, and advantages of the present inventionwill become more apparent from the following detailed description of thepreferred embodiments and certain modifications thereof when takentogether with the accompanying drawings in which:

[0012]FIG. 1 is an isometric view of an improved spacing device 20according to a first embodiment of the present invention.

[0013]FIG. 2 is a front perspective view of the spacing device 20 as inFIG. 1.

[0014]FIG. 3 is an end perspective view of the spacing device 20, as inFIGS. 1 and 2, clearly showing the T-shaped cross-section 40.

[0015]FIG. 4 is an end perspective view of polymer planks 100, 102 thatwill be spaced at an appropriate interval by using a first embodiment ofthe present invention.

[0016]FIG. 5 is an end perspective view of the spacing device 20demonstrating its usage in positioning polymer planks 100, 102 at anappropriate interval.

[0017]FIG. 6 is an end perspective view of the spacing device 20demonstrating its usage in positioning polymer planks 100, 102 as inFIG. 5.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0018] FIGS. 1-3 are, respectively, isometric, front, and endperspective views of an improved spacing device 20 according to a firstembodiment of the present invention.

[0019] The spacing device 20 according to the present inventiongenerally comprises a straight length of rigid material 30 possessing aT-shaped cross-section 40. The material 30 may be aluminum or polymerextruded into a T-shaped cross-sectional configuration. However, anydurable, lightweight, economical substance that can be formed with aT-shaped cross-section may be used to fabricate the present invention.Examples may include polymers such as PVC or nylon. The presentinvention's design is simple and straightforward, and can beeconomically manufactured and sold.

[0020] The vertical element (or leg) 42 of the “T” serves two purposes.First, by means of its width ‘W’ it establishes the spacing between thepolymer planks of a deck (see discussion associated with FIG. 4 below).The width ‘W’ of the leg 42 may vary and will depend uponapplication-specific parameters such the width of each plank (to addressdrainage issues) or the degree of “open-ness” desired by the owner ofthe building to which the deck is being added. The second purpose of thevertical element 42 is to serve as an abutment against the underlyingjoists of the deck to keep the horizontal element 44 above the top ofthe planks, thereby making extraction much easier. In this regard, theheight ‘H’ of the leg 42 is preferably just slightly more than thethickness of the planks with which the spacing device 20 is to be used,and 1½″ is a suitable height for common planks. When inserted, thebottom of the vertical element 42 will abut the underlying joists, andthis forces the top of the spacing device 20 to protrude over theplanks.

[0021] To further simplify extraction, the horizontal element 44possesses a width ‘X’ that is preferably equal to ‘W’ plus ½″ thatprevents the present invention from falling through the spaceestablished by the leg 42, and a thickness ‘Y’ that provides for theeasy gripping of the device 20 for extraction from between two planksonce both have been firmly attached to all appropriate supportcross-members.

[0022] The two side faces 46 of the leg 42 provide surfaces on which avariety of indicia 48 may be inscribed. For example, the indicia 48 a onone side may include all, or part, of the name of the device 20 or anadvertiser. The indicia 48 b on the flip side preferably includes rulermarkings to make the device multi-functional.

[0023] The top face of the device carries a 16″ O.D. ruler indicia tohelp space nails when they are pounded in.

[0024] The overall length ‘L’ of the present device 20 should besufficient so that only one needs to be used to align a 16-20′ plank,and a length L of 1′8″ has been found sufficient for this purpose.

[0025] FIGS. 4-6 are end perspective views of polymer planks 100, 102and the use of the spacing device 20 in positioning them at anappropriate interval.

[0026] With reference to FIG. 4, two planks 100, 102 are shown restingon one or more supporting joists 110. Plank 100 has been firmly attachedby screws (not shown) to the supporting joists 110. A second plank 102is unattached to the joists 110 and positioned a distance ‘D’ from theattached plank 100. The most efficient use of the device 20 requiresdistance ‘D’ to be greater than the width ‘W’ of the device's leg 42,but less than the width ‘X’ of its horizontal section 44.

[0027] As shown in FIG. 5, the spacing device 20 is then placed in thegap between the two planks 100, 102. The unattached plank 102 is pushedor pulled, in the direction of arrow 105, toward the attached plank 100until its surface 103 contacts the spacing device 20. This pushing orpulling is best accomplished with an existing decking tool such asavailable from Stanley®, which gives a long handle and provides greatleverage for pushing or pulling the joists against the deck spacer ofthe present invention.

[0028] While the positions of the planks 100, 102 and the spacing device20 are maintained as shown in FIG. 6, screws (not shown) are insertedthrough plank 102 to firmly attach it to the joists 110. Once the plank102 has been firmly attached to the joists 110, the device 20 isextracted for reuse by grasping the ends 45 of the horizontal section44.

[0029] Generally, the planks 100, 102 are of a length (3 to 12 feet)that require the simultaneous use of two spacing devices 20. Whenexactly two are utilized, the devices 20 are placed in position betweenthe planks 100, 102 at points near the ends of the planks 100, 102.However, circumstances will arise where only one device can be used(typically when the length of the planks are less than 3 feet), or it isrecommended that three or more be utilized (planks longer than 12 feet).When these situations arise, the spacing device(s) 20 may need to bepositioned at points along the planks 100, 102 other than the ends. Thefunctionality of the spacing device 20 is not compromised by use atpoints other than the end of the planks 100, 102.

[0030] Using a combination of an existing decking tool with the presentinvention, deck installation time can be cut to a fraction, and theresults are excellent because the polymer planks of the deck areconsistently placed.

[0031] Having now fully set forth the preferred embodiment and certainmodifications of the concept underlying the present invention, variousother embodiments as well as certain variations and modifications of theembodiments herein shown and described will obviously occur to thoseskilled in the art upon becoming familiar with said underlying concept.It is to be understood, therefore, that the invention may be practicedotherwise than as specifically set forth in the appended claims.

I claim:
 1. A spacing device comprising: a length of substantially rigidmaterial having a uniform cross-section comprised of a substantiallyrectangular horizontal member and a substantially rectangular verticalmember intersecting one side of said horizontal member; wherein saidhorizontal member and vertical member are joined at a right anglethereby giving said length of material a T-shaped cross-section forplacement between two elongate articles in need of spacing.
 2. Thespacing device according to claim 1 wherein said vertical memberpossesses two substantially parallel faces suitable for inscribingindicia.
 3. The spacing device according to claim 2 wherein said indiciacomprise alphanumeric characters.
 4. The spacing device according toclaim 2 wherein said indicia comprise a ruler.
 5. The spacing deviceaccording to claim 1 wherein said horizontal member possesses a top facehaving a 16″ length indicia inscribed thereon.
 6. The spacing deviceaccording to claim 1 wherein a height of said vertical member isslightly more than the thickness of the planks with which the spacingdevice is to be used.
 7. The spacing device according to claim 6,wherein a height of said vertical member is 1½″.
 8. The spacing deviceaccording to claim 6, wherein a width of said horizontal member is equalto a thickness of said vertical member plus ½″ to prevent the spacingdevice from falling through joists.
 9. The spacing device according toclaim 6, wherein said horizontal member and said vertical member are ofuniform length.
 10. The spacing device according to claim 9, whereinsaid horizontal member and said vertical member are 20″ in length.